Laser welding systems and methods

Abstract

A laser processing configuration, in particular for laser welding of three-dimensional components, includes a first optical element for dividing a laser beam into at least two partial beams, and a second optical element for focusing the partial beams. The first and the second optical element are stationarily mounted in a common housing disposed on a laser processing head in such a manner that it can be rotated.

1. A laser processing machine comprising
 a laser configured to generate a laser beam; 
 a laser head containing a beam divider and a beam focuser, the beam divider configured to divide the laser beam into multiple partial beams, the focuser configured to focus the partial beams for processing of a workpiece; and 
 a beam guidance system disposed between the laser and the laser head and configured to direct the laser beam to the beam divider of the laser head; 
 wherein the laser head includes a housing to which the beam divider and focuser are fixed, the laser head housing being rotatable with respect to the beam guidance system about a positioning axis, so as to vary an output direction of the laser head while maintaining focus of the partial beams. 
 
   
   
     2. The machine of  claim 1  wherein the beam divider comprises a mirror. 
   
   
     3. The machine of  claim 2  wherein the beam divider mirror has separate facets that meet at a ridge incident to the laser beam, such that a first portion of the beam strikes one facet of the mirror, and a second portion of the beam strikes another facet of the mirror. 
   
   
     4. The machine of  claim 3  wherein the ridge intersects the positioning axis, such that dividing of the beam is independent on rotational position of the laser head housing. 
   
   
     5. The machine of  claim 1  wherein the beam focuser comprises a mirror. 
   
   
     6. The machine of  claim 5  wherein the beam focuser mirror is sized to intercept all of the partial beams from the beam divider. 
   
   
     7. The machine of  claim 5  wherein the beam focuser mirror is parabolic. 
   
   
     8. The machine of  claim 1 , further comprising an adaptable mirror positioned to intercept and deflect the laser beam upstream of the beam divider and beam focuser, wherein the adaptable mirror is alterable to adjust focus. 
   
   
     9. The machine of  claim 8  wherein the adaptable mirror is configured to have a curvature alterable by water pressure changes. 
   
   
     10. The machine of  claim 8  wherein the adaptable mirror is secured to a second laser head housing, to which the laser head housing containing the beam divider and beam focuser is rotatably coupled. 
   
   
     11. The machine of  claim 10  wherein the intermediate housing is rotatable with respect to the beam guidance system about a second positioning axis. 
   
   
     12. The machine of  claim 1  wherein the beam divider and beam focuser are positioned to intercept the beam traveling along a first direction, and to redirect the partial beams in a second direction. 
   
   
     13. The machine of  claim 12  wherein the second direction is substantially perpendicular to the first direction. 
   
   
     14. The machine of  claim 12  wherein the first direction is substantially aligned with the positioning axis. 
   
   
     15. The machine of  claim 1  further comprising a workpiece support positioned to support a workpiece while the workpiece is processed with the focused partial beams. 
   
   
     16. The machine of  claim 1  comprising a laser welder. 
   
   
     17. A method of processing a workpiece with a laser beam, the method comprising
 generating a laser beam; 
 directing the generated beam with a beam guidance system to a laser head having a beam divider, a beam focuser, and a housing containing both the beam divider and beam focuser and rotatable about a positioning axis relative to the beam guidance system; 
 intercepting and dividing the directed beam with the beam divider to form multiple partial beans; 
 focusing and redirecting the multiple partial beams; 
 engaging a workpiece with the redirected, focused, partial beams to process the workpiece; and 
 rotating the laser head housing about the positioning axis to vary an output direction of the laser head while maintaining focus of the multiple partial beams. 
 
   
   
     18. The method of  claim 17  wherein rotating the laser head housing about the positioning axis alters an output direction of the laser head.